Aerospace AMAM for SpaceMakers

Weekend project: 3D print a replica of the the 3D printed SpaceX helmets

Adafruit gives you everything you need

Stay up to date with everything that is happening in the wonderful world of AM via our LinkedIn community.

By now you’ve probably heard that the helmets for SpaceX’s super-stylish spacesuits were custom-made for each of the two astronauts using a 3D printing process. This weekend you can become part of space history being made by 3D printing your own replica of the helmets thanks to a tutorial on popular maker website Adafruit.

The real SpaceX helmets were created by the talented Hollywood designer Jose Fernandez, of Ironhead Studios. As the New York Times reported in an article dedicated to these “tuxedos of space”, Fernandez is a costume designer who worked on Batman Vs Superman, The Fantastic Four, The Avengers, X-Men II and more. According to the NYT, movie director Michael Bay revealed that for spacesuit helmet in the movie Armageddon he turned to “people around Hollywood that are […] expert spacesuit helmet designers. It’s a very specialized craft.”

3D printed SpaceX helmets

To get the first prototype Musk went to that source rather than the usual Air Force and Navy contractors. The NYT reports that when Mr. Fernandez was first contacted he did not know what SpaceX was. However, he did have extensive experience designing helmets for movies, as shown by Ironhead Instagram page, including Tom Cruise’s helmet in Top Gun: Maverick.

View this post on Instagram


A post shared by Ironhead Studio (@ironhead_studio) on

3D printed SpaceX helmets

Be like Elon

SpaceX made it clear that 3D printing was used to produce the custom helmets worn by NASA astronauts Doug Hurley and Bob Behnken during the historic Crew Dragon launch.

It’s not clear what technology or materials was used for SpaceX’s helmets. FDM is a viable possibility due to the wider availability of advanced materials such as PEKK and flame retardant ULTEM and the low number of parts needed, however SLS now also supports PEKK.

The parts in the kit published on Adafruit are designed to be 3D printed with standard FDM based machines. The STL files are oriented to print “as is”, however they require tight tolerances that might need adjustment of slice settings.

The parts can further be separated into small pieces for fitting on printers with smaller build volumes. Note: a STEP file is included for other 3D surface modeling programs such as Onshape, Solidworks and Rhino. The Adafruit SpaceX Helmet was originally designed by Nathan O. The files are open to remix and they feature nice details. The parts have been modified to fit all of the electronics and available to download.

3D printed SpaceX helmets

Consumer Products AM 2024

This new market study from VoxelMatters provides an in-depth analysis and forecast of polymer and metal AM in the consumer products industry across the three core segments of the additive manufactu...

Related Articles

Leave a Reply

Your email address will not be published. Required fields are marked *

Back to top button
Close Popup
Privacy Settings saved!
Privacy Settings

When you visit any web site, it may store or retrieve information on your browser, mostly in the form of cookies. Control your personal Cookie Services here.

These cookies are necessary for the website to function and cannot be switched off in our systems.

Technical Cookies
In order to use this website we use the following technically required cookies
  • wordpress_test_cookie
  • wordpress_logged_in_
  • wordpress_sec

Decline all Services
Accept all Services


Join our 12,000+ Professional community and get weekly AM industry insights straight to your inbox. Our editor-curated newsletter equips executives, engineers, and end-users with crucial updates, helping you stay ahead.